FM Global

Property Loss Prevention Data Sheets

5-21
October 2012
Page 1 of 12

METAL HALIDE HIGH-INTENSITY DISCHARGE (HID) LIGHTING

Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 2
1.1 Changes ............................................................................................................................................ 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 High-Intensity Discharge Lighting .................................................................................................... 2
2.1.1 Introduction ............................................................................................................................ 2
2.1.2 Protection .............................................................................................................................. 2
2.1.3 Operation and Maintenance .................................................................................................. 2
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 3
3.1 Loss History ..................................................................................................................................... 3
3.1.1 High-Intensity Discharge Lighting ......................................................................................... 3
3.2 Illustrative Losses ............................................................................................................................ 7
3.2.1 Retail Store ............................................................................................................................ 7
3.2.2 Storage of Granular Plastic Pellets ....................................................................................... 7
3.2.3 Multi-tenanted Warehouse .................................................................................................... 7
3.2.4 Synthetic Fabric Rack Storage ............................................................................................. 8
3.2.5 Roll Paper Storage ................................................................................................................ 8
3.2.6 Plastic and Paper Storage Warehouse ................................................................................. 8
3.2.7 Computer Equipment Assembly Plant Storage ..................................................................... 8
4.0 REFERENCES ....................................................................................................................................... 9
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 9
APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 10
APPENDIX C SUPPLEMENTAL INFORMATION ...................................................................................... 10
C.1 OSHA Technical Information Bulletin, TIB 00-09-13, Possible Failure Mode of
Metal Halide Lamps ............................................................................................................................... 10

List of Figures
Fig.
Fig.
Fig.
Fig.
Fig.

1.
2.
3.
4.
5.

Schematic of HID lamp ...................................................................................................................... 4

Arc tube configuration ........................................................................................................................ 5
Protected lamp configuration ............................................................................................................. 6
OSHA TIB (page 1) .......................................................................................................................... 11
OSHA TIB (page 2) ......................................................................................................................... 12

2009-2012 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.

5-21

Metal Halide High-Intensity Discharge (HID) Lighting

Page 2

FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet addresses the ignition potential from the rupture of metal halide high intensity discharge
(HID) lighting.
1.1 Changes
October 2012. The following was done to address protection in existing locations (Section 2.1.2.1):
Changed title from Electrical Fires to Metal Halide High-Intensity Discharge (HID) Lighting.
Added lamp replacement recommendation.
Removed all references relating to adequacy of sprinklers
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 High-Intensity Discharge Lighting
2.1.1 Introduction
Apply these recommendations to any wattage metal halide HID lighting.
2.1.2 Protection
2.1.2.1 Existing Locations
Where unprotected metal halide HID lamps are installed, ensure that replacement lamps are protected or
borosilicate or tempered soda lime glass external shields are provided.
2.1.2.2 New Facilities
Where metal halide HID lamps are to be installed provide the following:
A. Fixtures and lamps that meet UL 1598, Luminaires, or the equivalent acceptable IEC or local standard,
and
B. Protected lamps or enclosed fixtures with borosilicate or tempered soda lime glass external shields.
C. Where ignition sources must be tightly controlled due to the presence of readily ignited or highly
smoke- sensitive materials, provide enclosed fixtures (external shields). Use external shields made of
borosilicate or tempered soda lime glass that do no leave any gaps between the glass and the fixture. The
lamp containment barrier will prevent fragments of hot glass or quartz from falling and igniting combustibles
under them. Follow the lamp manufacturers instructions for installation of the lamp to ensure proper
application of the lamp, fixture, and associated auxiliary devices.
2.1.3 Operation and Maintenance
2.1.3.1 Cycle off HID lamps that do not have borosilicate or tempered soda lime glass external shields for
at least 15 minutes each week.
2.1.3.2 Perform the following operation and maintenance on all HID lamps:
1. Maintain a record of lamp installation date and recommended manufacturers service life.
2. Replace the lamp at or before the end of its rated life, preferably by group relamping.
3. Replace the lamp if the outer glass bulb has been scratched, cracked, or damaged in any way.
4. Protect the lamp from contact with liquid, moisture, dust, dirt, oils, etc.
5. Never touch the lamp with bare hands.
2.1.3.3 Always follow the requirements shown on manufacturers bulletins.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

FM Global Property Loss Prevention Data Sheets

5-21
Page 3

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Loss History
High Intensity Discharge (HID) lights can create an ignition source if they shatter. Over the last decade,
FM Global clients reported an average of about 3 such incidents a year, with the loss experience largely
involving only metal halide lights.
Many, but not all, of the lamp manufacturers have stated that metal halide HID lamps can fail violently.
FM Global believes the possibility of violent failure of this type of lamp extends to all manufacturers.
3.1.1 High-Intensity Discharge Lighting
3.1.1.1 Introduction
High-intensity discharge (HID) electric lighting includes mercury vapor, metal halide, and high-pressure
sodium lamps.
This type of lamp (Fig. 1) produces light by electrically exciting a mixture of metallic vapor and halides. The
lamp consists of a fused silica/quartz arc tube that confines the electric discharge and the associated gases.
The arc tube is dosed with mercury, metal halide salts and filled with the inert gas, argon. The arc tube is
under a vacuum, 0.39 atm./0.5 psi when the lamp is at ambient temperature and de-energized. The arc tube
is enclosed in a glass bulb or outer jacket to exclude air. The bulb is filled with nitrogen, which prevents
oxidation of metal parts, stabilizes the operating temperature, and reduces UV radiation. High-intensity
discharge lighting operates at very high temperatures and pressures (up to 2000F [1100C] and 50 psi [350
kPa]). Because it is a discharge lamp, it does not instantly re-light and will take some time (two or more
minutes) to reach full brightness after a power loss.
3.1.1.2 Available Capacity (Wattage) of Lamps
Generally, the following wattage lamps are available: 75, 100, 150, 175, 250, 400, 1000, and 1500 W. The
capacity of the lamp can be read off the markings on a spare lamp; purchase orders may also confirm the lamp
type in use. ANSI markings (used by all American and some European and Japanese manufacturers) consist
of five letters or numbers; the first letter denotes the type of lamp (H for mercury, M for metal halide, S or
high-pressure sodium). The lamp capacity is listed after the five letters or numbers. For example, M95PK400/BVU stands for a metal halide lamp with a nominal wattage of 400 W.
3.1.1.3 Burning Position
The lamp is designed to operate in a specific orientation in respect to the base. Typical positions are horizontal,
vertical base up, or vertical base down. Again, the lamp manufacturer will specify the burning position. The
wrong burning position will increase the likelihood of a violent failure.
3.1.1.4 Lamp Cycling
Many manufacturers recommend that continuously operated unshielded HID lamps be cycled off for a
15-minute period every week. HID lamps that continuously operate are not stressed in the same manner
as lamps that are periodically turned off. Cycling the lamp(s) allows for the lamp(s) to cool and frequently will
permit malfunctions to occur in a less harmful manner. If there are imperfections in the lamp, it may then
fail in a passive manner and will not ignite upon re-energizing. While cycling is not a guarantee that the lamp
will not fail during operation, it can reduce the potential.
3.1.1.5 Shrouded Lamps
A typical shrouded HID lamp is shown in Figure 3. The shroud may be constructed of quartz, alumina silicate,
or steel mesh. Lamps with this design that have passed a consensus NEMA industry-developed test are
rated as O bulbs for use in open fixtures. Based on this testing, these lamps are expected to always contain
arc tube fragments in the case of a violent arc tube rupture. (Older lamps of this type may have an MP
rating rather than the newer O rating.) This test was developed based on shrouded lamps and is only
appropriate for lamps with that type of construction.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

FM Global Operating Standards

5-21
Page 4

Fig. 1. Schematic of HID lamp

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

5-21

FM Global Property Loss Prevention Data Sheets

Page 5

ARC TUBE
CONFIGURATION
Bi -metallic
switch to shut off starter
probe once arc between top
and bottom electrode plates
is established
Starter probe

Failure area 2 :
failure will occur here and the
result will not be passive
Outer glass - termed bulb
material = borosilicate glass

Area between bulb and

arc tube filled with nitrogen
for thermal, color clarity
reasons filled to
1/4 to 1/2 atmospheres
(3.6 to 7.3 # psi ) @ ambient

Note: Major internal parts have

not been included
for display purposes

Argon
filled
(operating press
3 to 3.5 atmos
(44 to 50 psi)
0.039 atm
(0.5 psi )
@ ambient

Not to Scale

Failure area1 # : # due to starts,

de- vitrification # will occur
and then a small crack will
occur and argon will leak out or
nitrogen will leak in to
extinguish bulb - normally
passive failure

De-vitrification = the process

by which glassy texture of
of a material is converted
into a crystalline texture

Fig. 2. Arc tube configuration

A recent enhancement to HID fixtures that are designed for only O rated lamps is that they have a special
socket that only O rated lamps with special bases can fit into and operate. These O rated lamps will also
work in standard sockets.
By comparison, unshrouded lamps may be rated S or E. The S rating allows installation in an open
fixture provided certain precautions are followed, such as orientation and cycling. S rated lamps are
available in 360, 400, and 1000 watt ratings for use only in a vertical orientation. The S rating is based on
empirical field experience that the lamps rarely explode if cycled weekly, and group relamping is performed
in accordance with manufacturer recommendations. Lamps with an E rating are for use only in enclosed
fixtures.
3.1.1.6 Service Life of Lamps
The specifications of various lamp manufacturers indicate that the life expectancy of lamps can range from
approximately 3000 hr. (approximately 4 months) to 20,000 hr. (approximately 214 years).

2009-2012 Factory Mutual Insurance Company. All rights reserved.

5-21

Metal Halide High-Intensity Discharge (HID) Lighting

Page 6

FM Global Property Loss Prevention Data Sheets

Fig. 3. Protected lamp configuration

The following table presents a range of operating service hours as found in product literature from various
manufacturers.
Lamp Wattage, W
100
150
175
250
400
1000
1500

Service Life, hr
6,000 to 10,000
10,000
6,000 to 7,500
10,000
15,000 to 20,000
9,000 to 12,000
3,000 to 12,000

Factors that affect lamp life include high and low operating voltages, extremely high operating temperature,
and marginally operating auxiliary equipment (ballasts, capacitors, ignitor, and/or power supplies. Most lamps
fail to reignite at end of life. This is due to either the argon leaking out of the arc tube, or nitrogen (ion inhibiter)
leaking into the arc tube. Most manufacturers recommend group relamping after approximately 60%-75%
of rated life. Light output and color shift occur over the life of the lamp. This is the result of the loss of lightproducing chemicals within the arc tube and the darkening of the inner walls of the arc tube. The light output
of HID lamps decreases to approximately 60% of initial rated light output at about half of its rated life.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

FM Global Property Loss Prevention Data Sheets

5-21
Page 7

3.1.1.7 Failure Mode

Failure of a HID lamp can occur in several ways (Fig. 2). Scratches on the outer envelope, direct contact
with water, or excessive pressure can cause these lamps to break. HID lamps and their arc tubes operate
at extremely high temperatures and may shatter as a result of missapplication, incorrect burning position,
system failure, or other factors. De-vitrification of the arc tube glass occurs when the quartz reacts with the
halogen gas. A small crack will occur normally in the vicinity of the electrode, and either the argon will leak out
of the arc tube or the nitrogen gas will leak into the arc tube. Normally the lamp will fail to reignite. The
probability that the arc tube will implode towards end of life increases significantly. If the lamps are cycled
on and off periodically, they are much more likely to fail to restart rather than fail violently at end of life.
If an arc tube ruptures under normal operating conditions, the arc tube fragments can penetrate the outer
bulb if a shroud is not effective or present. Extremely hot glass and lamp parts can be released into the
surroundings if fragments are not contained by the shroud or an external shield, causing a risk of fire if
combustible materials are present.
3.2 Illustrative Losses
3.2.1 Retail Store
Two sprinklers promptly controlled a fire started by a high-intensity discharge (HID) lamp. The bulb jacket
parted and spewed hot quartz pieces onto a plastic light diffuser beneath and the occupancy below, during
an unattended period at a retail store. Sprinklers controlled the fire and limited damage.
The arc tube of the HID lamp ruptured and discharged hot (estimated 2000F [1100C]) quartz onto the plastic
light diffuser beneath, which in turn dropped hot or flaming matter on the occupancy below.
The manufacturer had apparently advised purchasers of these HID lamps of this potential failure mode. A
program to replace the plastic light diffusers beneath the lamp was being investigated. The lamp may have
gone beyond its 10,000-hr rated life. The life rating is not described on the package in which the replacement
bulbs are received. The preventive maintenance advice from the manufacturer (to turn the lamps off at least
15 minutes a week) was apparently being followed at this store. Energy conservation was also a factor in
the lighting on and off cycle.
3.2.2 Storage of Granular Plastic Pellets
A fire started in double-row rack storage of bags containing granular plastic. It was probably caused by a
defective electrical component associated with the lamps. The fire was promptly extinguished by the ceiling
sprinkler system. Damage was limited to two burnt pallet loads of stock, and wetted adjacent storage.
Suspected cause of the fire is an arc on the mercury vapor lamp ignition condensor, resulting in hot particles
falling on and igniting the storage in the rack. This warehouse is provided with mercury vapor lamps (125
to 250 W, 220 V) at the ceiling level. It could not be ascertained when these lamps were installed, but it was
reported that this lighting system is approximately twenty years old. An ignition condensor of a mercury vapor
lamp had been damaged in normal operation. This electrical component was not fully enclosed, thus allowing
molten metal to escape.
3.2.3 Multi-tenanted Warehouse
Hot fragments released from a ruptured metal halide lamp or fixture are the probable cause of a fire that
resulted in damage to client storage at this leased warehouse.
The storage involved in the fire was reported to be 6 to 8 ft (1.8 to 2.4 m) high and consisted mostly of plasticwrapped and cartoned nylon gear bags and some corrugated carton flats. Higher storage ranging from
8 to 12 ft (2.4 to 3.7 m) high surrounded the storage area across the narrow access aisles from the area of
origin. This storage included mostly vinyl inflatable rafts. The light fixtures were at least 10 ft (3.0 m) above
the highest storage in the building, and about 18 to 20 ft (5.5 to 6.1 m) above the storage involved in the
fire.
The building lights are turned off each night. The original lights in the warehouse, and those located over
this fire incident and the office, were reported to be 1,000-W metal halide lamps. None of the fixtures have
shields fitted.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

5-21

Metal Halide High-Intensity Discharge (HID) Lighting

Page 8

FM Global Property Loss Prevention Data Sheets

This is a no-smoking facility, except for the office and breakroom. Indications are that this policy was strictly
observed. No hot work had been conducted on site for months.
3.2.4 Synthetic Fabric Rack Storage
Sparks from a ruptured overhead mercury vapor lamp ignited rolls of synthetic fabric stored in multiple-row
racks to 16 ft (4.9 m) high at a cloth-finishing plant. Ninety-six ceiling sprinklers operated. In-rack sprinklers
were not provided. Ceiling sprinklers, strong water supplies, and prompt fire service response limited fire
damage. Smoke and water damage were extensive.
The mercury vapor lamps did not have an enclosure to keep sparks from spreading to storage. Lack of a
wall between the warehouse and a manufacturing building allowed smoke to damage production machines.
Lack of in-rack sprinklers allowed the fire to operate an excessive number of ceiling sprinklers.
3.2.5 Roll Paper Storage
The bursting of a mercury vapor lamp is the probable cause of a fire occurring in a roll paper storage area
at a tissue products manufacturing plant. The water density available from the hydraulically designed
sprinkler system was inadequate for the occupancy because the system was designed to protect paperconverting lines. Paper rolls were stored on end, two high, to a height of 17 ft (5.2 m). The lamp that probably
started the fire was the only one in the area not provided with a safety cover.
Damage was limited by a strong water supply and an effective emergency response team.
A total of about 2,000 tons (1,800 metric tons) of roll paper were burned, charred, or wet. Also damaged
were aluminum roof panels, plastic skylights, and electric lights and wiring. Although paper-converting
machines were not damaged, production was interrupted for two days for cleanup.
3.2.6 Plastic and Paper Storage Warehouse
A hot fragment from a ruptured metal halide lamp or fixture is the probable cause of a fire in a 200,000 ft2
(19,000 m2) warehouse with two tenants. The sprinklered building has precast concrete walls and a Class II
insulated steel deck roof. The tenants stored promotional merchandise and paper business records.
The operation of five sprinklers confined the fire to a 500 ft2 (46 m2) area used for the storage of plastic
and paper promotional items stored on pallets to a height of 8 ft (2.4 m). Water damage occurred over an
area of 10,000 ft2 (930 m2). Smoke damage was observed throughout the building. No structural damage was
reported.
3.2.7 Computer Equipment Assembly Plant Storage
An unshielded, 400-W metal halide lamp over rack storage popped, igniting rack storage of plastics at a
computer equipment assembly plant. Sprinklers operated and controlled the fire. Nonthermal damage
accounted for most of the loss.
About three years before the fire, FM Global had determined that the rack storage was inadequately protected
and had recommended an upgrade. About two years later, the sprinkler system was reinforced in accordance
with accepted plans.
About two years before the fire, FM Global had also recommended the metal halide lamps be cycled weekly.
The client established a weekly cycling program, so the recommendation was reported as completed some
four months before the fire. Unfortunately, in those four months, key personnel changes occurred and the
cycling program was not being followed.
This loss illustrates the danger metal halide lights present as an ignition source and the importance of having
adequate sprinkler protection.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

FM Global Property Loss Prevention Data Sheets

5-21
Page 9

4.0 REFERENCES
UL 1572, High Intensity Discharge Lightning Fixtures
UL 1598, Luminaires
APPENDIX A GLOSSARY OF TERMS
Accessibility Barrier: A material provided to limit access to uninsulated live parts; and live parts insulated
with materials not intended to be subject to user contact. All or part of the barrier may also serve as an
enclosure as defined below.
Arc tube: A completely sealed quartz tube where the electrical discharge (arc) occurs.
Ballast: An auxiliary piece of equipment designed to start and properly control the flow of power to the gas
discharge light source such as HID lamps.
Base: The end of the lamp that inserts into the lamp socket.
Bulb: The outer jacket or envelope of a lamp, is the glass enclosure that covers the frame and arc tube
assembly.
Enclosure: A material provided to enclose electrical parts and components that may be considered to involve
a risk of fire. All or part of the enclosure may also serve as an accessibility barrier as defined above or as
a recessed housing as defined below.
Field-Connected Ballast: A ballast that may or may not be provided with the fixture and that is intended to
be electrically connected to the fixture during installation. The ballast may be mounted on the fixture or
mounted remotely.
High Intensity Discharge (HID) Lamp: A general term for mercury, metal halide and high pressure sodium
lamps. HID lamps contain compact arc tubes which enclose various gases and metal salts operating at high
pressures and temperatures.
High Pressure Sodium Lamp: An HID lamp which produce light by an electrical discharge through sodium
vapor operating at high pressure and temperature.
Lamp: The device, commonly called a light bulb or bulb, intended to be inserted into a lampholder (socket)
to produce light.
Lamp Containment Barrier: A barrier that consists of the top, sides, and bottom that enclose the lamp
compartment. The barrier may consist of a metal housing (recessed or otherwise), a polymeric enclosure,
a glass diffuser or lens, a metal canopy, a metal screen, or the like.
Luminaire: A complete lighting unit consisting of a lamp, ballast, as required together with the parts designed
to distribute the light, position and protect the lamps and connect them to the power supply (fixture).
Mercury Lamp: An HID lamp in which most of the light is produced by radiation from excited mercury vapor
operating at high pressure and temperature. Phosphor coatings on some lamp types add additional light
and improve color rendering.
Metal Halide Lamp: A high-intensity discharge (HID) lamp in which the major portion of the light is produced
by radiation of metal halides and their products of dissociation.
Pendant Fixture: A fixture that is supported by and suspended from an outlet box by a chain, cord, stem,
or cable.
Recessed Fixture: A fixture intended to be installed in a hole in a wall, ceiling, or in-ground surface such
that all or part of the fixture is behind the mounting surface.
Recessed Housing: The metal of a recessed fixture that serves to close off the hole provided in a ceiling
or wall surface to mount the fixture. It does not necessarily enclose wires or the like.
Remote Ballast: A ballast that is not mounted on a fixture or one that is mounted on the fixture 18 in. (457 mm)
or more from the recessed housing as measured from the nearest point on the ballast to the nearest point
(other than an incidental projection) on the recessed housing. The ballast may or may not be provided with the
fixture.
Shroud: A quartz tube around the arc tube.

2009-2012 Factory Mutual Insurance Company. All rights reserved.

5-21

Metal Halide High-Intensity Discharge (HID) Lighting

Page 10

FM Global Property Loss Prevention Data Sheets

APPENDIX B DOCUMENT REVISION HISTORY

October 2012. The following was done to address protection in existing locations (Section 2.1.2.1):
Changed title from Electrical Fires to Metal Halide High-Intensity Discharge (HID) Lighting.
Added lamp replacement recommendation.
Removed all references relating to adequacy of sprinklers
June 2009. Appendix B, Document Revision History was updated.
May 2002, DS 5-21, Electrical Fires, was published as a May 2002 revision of the January 2001 release.
May 2001, DS 5-21, Electrical Fires, was published as a May 2001 revision to the January 2001 release.
January 2001, DS 5-21, Electrical Fires, was published as a document superseding the September 2000
release.
October 1999, DS 5-21, Electrical Fires, was published as a revised operating standard and as a new public
data sheet.
APPENDIX C SUPPLEMENTAL INFORMATION
C.1 OSHA Technical Information Bulletin, TIB 00-09-13, Possible Failure Mode of Metal Halide Lamps

2009-2012 Factory Mutual Insurance Company. All rights reserved.

Metal Halide High-Intensity Discharge (HID) Lighting

FM Global Property Loss Prevention Data Sheets

Fig. 4. OSHA TIB (page 1)

2009-2012 Factory Mutual Insurance Company. All rights reserved.

5-21
Page 11

5-21

Metal Halide High-Intensity Discharge (HID) Lighting

Page 12

FM Global Property Loss Prevention Data Sheets

Fig. 5. OSHA TIB (page 2)

2009-2012 Factory Mutual Insurance Company. All rights reserved.